ATTACHMENT_2_-_60SeriesSpec_Mod_04-09-19.docx

REVISION No. 2 CHANGE No.1

SPECIFICATION OR

STATEMENT OF WORK

COVER SHEET

TITLE

MTU 60 SERIES DDEC IV ENGINE OVERHAUL

OVERHAUL/RECONDITION SPECIFICATION

SPECIFICATION NUMBER

R-233-0614

ORIGINATED BY: Michael McHale DATE 09/17

ORIGINATOR'S COMMAND: SURFACE FORCES LOGISTICS CENTER (SFLC)

DEPARTMENT/DIVISION: SMALL BOAT PRODUCT LINE ENGINEERING CELL

INTERNAL REVIEWER DATE ______

SOWRB APPROVAL DATE

1.0 SCOPE

1.1 GENERAL - This specification is for the overhaul of a non-ready for issue 60 Series DDEC IV MTU marine engine and the attached Twin Disc MG 5114SC marine transmission to OEM specifications and standards. The engine and the attached transmission will be referred to as the “propulsion unit” in this specification.

The contractor will reassemble the marine engine with only MTU OEM equipment and parts, using Master Serial Number: 06R1041815 (Port Engine) and 06R1041805 (Stbd Engine). The contractor will reassemble the marine transmission with only Twin Disc OEM equipment and parts using Master Serial Number: SKV074 (Port Transmission) and SKW421 (Stbd Transmission).

The marine engine with attached hang-ons with the exception of the alternator shall be dynamometer tested, preserved, painted, and packaged. The marine engine (one of a pair) is installed in the U.S. Coast Guard 45 FT. Response Boat Medium (RBM). The engine will be provided to the contractor in a metal shipping container.

1.2 Government Furnished Property – The items are property of and managed by the USCG Surface Forces Logistics Center, Baltimore, MD.

2.0 APPLICABLE DOCUMENTS

2.1 Applicable Documents - The following documents form a part of this specification to the extent specified herein.

2.2 Government Documents – The following specifications and standards form a part of this specification to the extent specified herein. Unless otherwise specified, the documents listed here by number and date shall be those in the current Department of Defense Single Stock Point (DODSSP) for military specifications, standards, and related publications.

2.2.1 Military Specifications

a. MIL-L-21260E, 31 Jul 1998, Lubricating Oil, Grade 30

b. MIL-D-3464E, 21 Apr 87, Desiccant, Activated bag Comment by McHale, Michael P CIV: Removed c. reference for wooden crates. Engines are in re-usable metal containers.

2.3 Other Government Documents - The following documents form a part of this specification to the extent specified herein. The documents listed shall be by title and effective date, unless otherwise documented.

a. 000-0100, REV G, Dated 2/06, Bar Coding for SFLC Material

2.4 Commercial Documents – The following documents form a part of this specification to the extent specified here. The documents shall be the version listed by number and date from the referenced industry organization. Commercial documents may be listed in the Department of Defense Single Stock Point (DODSSP).

2.4.1 American National Standards Institute (ANSI) / National Conference of Standards Laboratories (NCSL)

a. ANSI/ASQC Q9001-2000, 13 Dec 2000, Quality Management System Comment by McHale, Michael P CIV: Changed as per CPD recommendation

b. ANS/ISO/IEC 17025:2017 for Part 1 and ANSI/NCSL Z540.3-2006 for Part 2, General Requirements for Calibration Laboratories and Measuring and Test Equipment Comment by McHale, Michael P CIV: Changed as per CPD recommendation. Comment by McHale, Michael P CIV: Changed as per CPD recommendation.

2.4.2 American Society for Testing and Materials (ASTM)

a. ASTM D 975-02 Dated 10 January 2002, Diesel Fuel Oils.

2.4.3 MTU Corporation

a. MTU 60 Series Service Manual MS25056/00E Dated 1/ 2012

b. MTU Preservation and Represervation Specifications A001070/01E Comment by McHale, Michael P CIV: Changed as per CPD recommendation

2.4.4 Twin Disc Corporation

b. Marine Transmission Owner’s Manual #1016313, Rev G January 2012. Comment by McHale, Michael P CIV: Changed as per CPD recommendation.

2.5 Specification Precedence - Any conflict between this specification and applicable documents identified in this specification shall be resolved in this order:

a. This specification

b. Applicable documents

2.6 Departure from Specification - Departure from this specification shall not be allowed unless approved by the Coast Guard Contracting Officer.

a. If the contractor finds it necessary to implement change or depart from applicable specifications, they shall request permission.

b. Request by contractors for change shall clearly describe the changes proposed, the reasons for and advantages of the changes proposed, and the contract’s price increase or decrease (if any) that would result.

3.0 REQUIREMENTS

3.1 General - The contractor shall overhaul the marine engine and transmissions within sixty (60) calendar days after approval of the Disassembly Report (Appendix B) by the Contracting Officer. The contractor shall provide all labor, equipment, special tools and materials required to accomplish the following sequence of activities:

a. Receive propulsion unit

b. Uncrate propulsion unit

c. Disassemble and clean propulsion unit

d. Submit Core Condition Report (Appendix A)

e. Submit Disassembly Report (Appendix B)

f. Overhaul/Recondition propulsion unit

g. Reassemble propulsion unit

h. Complete Time Compliance Technical Order (Appendix E)

i. Perform dynamometer testing (Appendix C)

j. Preserve

k. Paint NOTE: Due to S60 engine block special coating. The use of chemical cleaners or dip tanks are not permitted on the engine block internal unpainted surfaces.

l. Package and mark propulsion unit

m. Ship propulsion unit

3.2 Propulsion Unit Parts (Engines) – All MTU 60 Series parts listed in Appendix G & M are mandatory replacement parts. All other components and parts listed in Appendix H shall be replaced upon the contingency of inspection. Contingent parts shall be inspected for critical dimensions and wear limits and replaced as authorized by the Contracting Officer. All gaskets, seals, O rings and copper seals shall be replaced as new. All DDEC engine sensors, i.e. Jacket water coolant level, Jacket water temperature, Jacket water pressure, Lube oil pressure, Lube oil temperature, Turbo Boost pressure, Air box pressure, Fuel pressure, fuel temperature shall be replaced as new. The contractor shall use only MTU Original Equipment Manufacturer (OEM) parts meeting OEM specifications.

All engines supplied to the contractor under this contract shall be overhauled at an authorized MTU facility. Engines shall not be exchanged under the MTU REMAN program. The Government reserves the right to supply parts as Government Furnished Property (G.F.P.) at any time during the contract. The Government Furnished Property will be annotated on each task order as required.

Note: OPERATING HOURS ON THE ELECTRONIC CONTROL MODULE (ECM) SHALL BE ZEROED OUT AFTER SUCCESFUL COMPLETION OF THE ENGINE OVERHAUL.

3.3 Propulsion Unit Parts (Transmission) - All Twin Disc parts listed in Appendix J & M shall be a mandatory replacement. All gaskets, seals, O rings and copper seals shall be replaced as new. All marine gear switches and sensors, i.e. oil pressure, oil temperature shall be replaced as new.

The marine gear cooler p/n 23525273 shall be removed, cleaned and inspected for corrosion, leakage and integrity. If unacceptable the cooler shall be replaced as per the contingency parts list.

All other Twin Disc components and parts listed in Appendix K shall be replaced upon the contingency of inspection. Contingent parts shall be inspected for critical dimensions and wear limits and replaced as authorized by the KO. The contractor shall use only Twin Disc OEM parts meeting OEM specifications.

3.4 Oil Pressure – As per Appendix C, oil pressure requirements shall meet the following criteria in sequence:

a. During the entire 30-minute full power trial portion of dyno testing the oil pressure shall maintain a minimum of 50 psi at 2300 rpm’s.

b. Immediately after the full power trial the engine RPM shall be reduced to 600 RPM with no load. At which time, the oil pressure shall be no lower than 25 PSI.

3.5 Labor - All labor is to be performed by MTU certified and authorized machinists and mechanics.

3.6 Shipping Container Parts – The contractor shall replace the following parts for each container received:

3.7 Paint Requirements for Shipping Containers – As needed, all internal and external surfaces shall have any and all scale and loose paint removed and be primed as per SSCP-Paint 25 and painted with two coats of Color# Camouflage Gray, Color Number 36170 (FED STD 595B CHG NOTICE 1) using paint in accordance with A-A-2962A.

3.8 Core Condition Report - The contractor shall submit Appendix A to the contracting officer in writing within ten (10) calendar days after receipt of the propulsion unit. The contractor shall submit Appendix B to the contracting officer in writing within fifteen (15) calendar days after receipt of the propulsion unit.

3.9 Core Acceptance Criteria - The contractor shall accept the core based on a visual walk around inspection as per Appendix A. If during the internal core inspection the contractor identifies concerns with the core condition, conditions shall be negotiated.

3.10 Cumulative Tracking Report - The contractor shall maintain and submit to the contracting officer, by the 15th of the month, for the previous month; the Cumulative Tracking Report Appendix F, for all propulsion unit.

3.11 Documentation - This specification sets forth the requirements for the following documentation.

a. Core Condition Report, in accordance with Appendix A

b. Disassembly Inspection Report, in accordance with Appendix B

c. Engine Test Report, in accordance with Appendix C

d. Cumulative Tracking Report, in accordance with Appendix F

3.12 Time Compliance Technical Order (TCTO) – All shall be completed as required by the Contracting Officer.

3.13 Warranty - A warranty of one year from installation or 1000 operating hours, whichever occurs first and 24 months of storage is required covering the entire marine engine. Storage commences upon receipt of engine at the designated Coast Guard facility. The contractor shall contact the field unit to arrange a resolution of a claim within 24 (twenty-four) hours after receiving notification by the Coast Guard of a warranty claim.

The contractor shall contact SFLC’s Contracting Officers Representative (COR) to evaluate the contractors proposed duration of warranty repair time.

In the event the Coast Guard decides the proposed warranty repair time compromises the Coast Guards mission and decides on removal/replacement, the contractor shall coordinate and fund all necessary shipping arrangements for the failed engine to be returned to the origin of the overhaul facility for repairs and returned to a designated Coast Guard facility after repairs have been completed.

The contractor shall repair or overhaul the failed engine to the condition level necessary for the contractor to honor a new full warranty including the zeroing of hours on the ECM. The contractor shall submit to the Contracting Officer an inspection report for approval containing any parts and pricing for any work/repairs that are required that were not a result of the specific casualty.

3.14 Failure Analysis – The contractor shall provide a failure analysis of the MTU 60 Series engine within 30 days of receipt upon request from the Contracting Officer. The test shall include but is not limited to the following objectives:

a. Dyno of the engine in an effort to emulate the failure cause.

b. Witness of engine disassembly at the Contractor’s facility by COR.

c. Visual inspection of engine and observance of any indication of failure.

d. Measurements of major engine components, bearings and bushings. Measurements will include critical dimensions and surface profilometry.

Component measurements and related data shall be recorded as necessary.

e. The inspection shall include removing all components necessary to conduct the investigation and to recover evidence of failure.

f. The suspected inferior parts/components and the inspection itself shall be performed using a high resolution digital camera.

3.15 Technical Representative Services – When requested by the Contracting Officer, the Primary Contractor shall provide an employed technical representative or local sub-contracted OEM certified technician personnel for discussion, resolution, and repair of technical problems. Troubleshooting and repair of technical problems may require Contractor personnel to travel to Coast Guard units. In correcting technical problems the Contractor shall abide by the following:

The Contractor employees visiting Government facilities shall wear an identification badge that, at minimum, displays the Contractors name, the employee’s photo, name, and badge expiration date.

The Contractor employees shall comply with all applicable Government regulations, policies, and procedures (e.g. fire, safety, sanitation, environmental protection, security, “off limits” areas, the wearing of parts of military uniforms, and possession of weapons) while on Government property. The Contractor shall ensure contractor employees present a professional appearance at all times. Contractor employee’s conduct shall not reflect discredit on the United States, the Department of Homeland Security or the U.S. Coast Guard.

The Government reserves the right to direct the Contractor to remove any Contractor employee from Government property for any reason deemed necessary. Removal does not relieve the Contractor of the responsibility to continue providing the service required. The Contracting Officer will provide written explanation to support any request to remove an employee.

3.16.1 Technical Services Performed Onsite – The Primary Contractor or sub-contracted technical representative(s) shall perform all services onboard the USCG vessel unless otherwise directed by the Contracting Officer.

3.16.2 Hours Of Operation – The Primary Contractor employees or sub-contracted technical representative(s) shall generally perform all work between the hours of 0800 and 1630 local time, Monday through Friday. However, Contractor employees may be required to work other than normal business hours, including weekends and holidays.

3.16.3 Locations – The services will primarily be required in vessel homeports located throughout the continental United States, Hawaii and Alaska.

3.17 Technical Representative Additional Requirements - In the event of problems arising in the availability of parts or logistical problems (such as shipyard availability, sub-contractor problems, crane service problems), the Technical Representative may be required to provide the services in stages requiring additional travel, lodging, etc. The Contracting Officer will make the decision for the representative to remain on site or reschedule the service.

If in the event the engine must removed from the boat to effect repairs, USCG personnel shall provide labor, tools and materials to remove and re-install the engine from the vessel.

3.18 Contractor Response – The Contractor shall be required to supply the Technical Representative to the designated location within Thirty-Six (36) hours after notification by the Contracting Officer.

The Contracting Officer shall establish the dates the Technical Representative is required.

3.19 Task Orders – The Surface Forces Logistics Center (SFLC) will issue a task order identifying where and when services are required. SFLC will supply the Contractor with the nature of the problem (if known) along with a Point of Contact and phone number. The Contractor shall be responsible to contact the Point of Contact within twenty-four (24) hours after notification by the Contracting Officer.

The results of the Representative's findings shall be provided in writing within twenty-four (24) hours of arrival. Approval to perform repairs shall be made by the Contracting Officer after evaluation from the USCG Contracting Officer’s Representative.

3.19.1 The report shall be in the format of Appendix I.

4.0 QUALITY ASSURANCE

4.1 General - The contractor shall maintain an inspection system, which shall ensure each item, offered to the Government for acceptance conforms to contract requirements. The system shall be documented and in compliance with ANSI/ASQC Q9003.

4.2 Records - The contractor shall as a minimum maintain records of all inspections and tests. The records shall indicate the nature and number of observations made, type of deficiencies found, and the corrective action taken. Records shall be furnished upon arrival of the Contracting Officer's Representative. In addition the Contractor shall indicate findings and overhaul remarks on the ACMS Record (Appendix L).

4.3 Contractors Calibration System - The contractor shall maintain a calibration and maintenance system to control the accuracy of measurement and test equipment used in the fulfillment of this contract in accordance with ANSI/NCSL Z540-3. The system shall include as a minimum, prescribed calibration intervals, source of calibration, and a monitoring system to insure adherence to calibration schedules. Calibration standards shall be traceable to the National Institute of Standards and Technology (NIST). Documentation in support of this requirement shall be readily available for Government review. Comment by McHale, Michael P CIV: Changes as per CPD recommendation.

4.4 Responsibility For Inspection - The Contractor shall be responsible for all inspections/test requirements specified herein. The contractor shall provide space, personnel, and test equipment to conduct all inspection requirements. All testing and inspection shall be at the Contractors facility or other facilities acceptable to the Government. The Government reserves the right to verify, witness or have performed any of the inspection/tests set forth in this specification where such inspections are deemed necessary to assure that supplies or services conform to the prescribed requirements. The contractor shall notify the Contracting Officer twenty one (21) working days prior to all inspections and tests.

4.5 Required Tests - Each marine propulsion unit provided under this contract shall be operationally tested under load to ensure minimum performance prior to acceptance. A test plan shall be submitted to the Contracting Officer thirty days after contract award addressing the final testing, inspection, and preservation to be accomplished by the contractor on all marine propulsion units. The test plan shall address the manufacture's requirements outlined in Appendix C and all other testing, inspection, and preservation requirements covered in this specification. Comment by McHale, Michael P CIV: Changed as per CPD recommendation.

4.6 Test Report - The contractor shall submit the test report, Appendix C, within seven (7) calendar days after completion of tests. The test report shall consist of the data obtained during the engine and marine gear test. One copy of the test report shall be packed and delivered with each propulsion unit delivered under this contract.

5.0 PRESERVATION PACKAGING AND MARKING

5.1 Internal Preservation – Preservation shall be completed as per MTU 60 Series Technical Manual A001070/01E 2012-02 for extended storage (Unless directed by contracting officer) and shall not be started until a successful dynamometer test has been completed and accepted by the COR. Engine Preservation shall be conducted for an engine with unfilled medium circuits to be stored for 60 months in climate-compatible packaging. Comment by McHale, Michael P CIV: Changed as per SFLC recommendation.

5.2 Engine Preservation (External) - Upon completion of final dyno testing, the marine propulsion unit shall be prepared as follows:

5.2.1 Surfaces shall be cleaned and free of grease/oil.

5.2.2 All loose scale and paint shall be removed; uneven paint layers shall be sanded smooth.

5.2.3 The following items will be masked and not painted:

5.2.4 On all exposed metal surfaces the Contractor shall apply one coat of red oxide primer p/n 08929667 (gallon can) or 08929668 (spray can) (2 to 3 mils MDFT) each to all components allowing primer to dry.

5.2.5 Two coats, IAW TT-E-489H approximately two (02) mils, total thickness 3-5 mils MDFT) shall be sprayed on all surfaces, allow a minimum of seven (07) hours drying time between coats. Color shall be DD workboat blue (gallon container) p/n SD152251 (spray can) p/n 23521542.

5.26 After sufficient drying time of DD workboat blue, apply two coats of clearcoat application, p/n 08929667 (gallon can) or p/n 23529990 (spray can).

5.2.7 When all paint is dry, all masking shall be removed.

5.2.8 All unpainted metal surfaces shall be coated with a light film of grease. (Except for hot surfaces).

5.2.9 Plug or cap all fittings/flanges and openings that may allow seepage from the engine during storage.

5.2.10 Engine and reduction gear shall be bagged and sealed IAW MTU Fluids and Lubricants Specification A001061/37E. Contractor shall use sealing material MIL-PRF-131K Class 1. Manufacturer Cadillac Products Packaging Company (CADPAK PL). Sealing guidelines: Temperature 400 degrees. Pressure 40 psi. Dwell 1 Second. Comment by McHale, Michael P CIV: Changed as per CPD recommendation.

5.2.11 The contractor shall attach to the interior base of the shipping crate 1 gallon bottle of Cummins "RESTORE" p/n CC 2610 heavy duty cooling system cleaner. The bottle shall be bubble packed and inserted in a separate container (5 gallon container) and secured to prevent spillage during shipping.

5.2.12 The contractor shall install the marine engine into the GFP supplied metal shipping container.

5.2.13 The contractor shall place a total of 16 units of desiccant bags conforming to MIL-D-3464E (activated bag 10 ounce equals 1 unit), in the interior of the shipping container in the receptacle provided.

5.3 Marking - Each shipping container shall be stenciled on the top of the two longest sides (two opposite sides if square) in accordance with 5.3.1. The bottom side of the container shall be stenciled with the appropriate NSN, engine serial number and model number on the two longest sides. The contractor shall ensure that the serial number and model number on the bottom and top of the container sides match the actual engine serial number and model number in the container.

a. Machine made stencils shall be used for all markings not on the bar code labels

b. All markings shall be in black print and at least 1/2" high.

5.3.1 This marking shall consist of the STOCK NUMBER, ITEM NAME, PART NUMBER, CONTRACT NUMBER, TASK ORDER NUMBER, GROSS WEIGHT (lbs), condition code CONDITION CODE “A”, unit of issue with quantity (i.e. 1-EA), and the words COAST GUARD SFLC MATERIAL. The format as follows:

PORT UNIT

MORE THAN TWO HIGH

STARBOARD UNIT

5.3.2 The following marking shall be placed on all four sides and the top of each box, in stenciled white print at least 1/2" high.

a. Reusable Crate, Do Not Damage, Remove Bolts Prior To Removing Cover, Use Forklift To Unload Do Not Lift By Cover

b. The contractor shall paint over all other markings not outlined in 5.3.1 and 5.3.2

5.3.3 Shipping – Prior to shipping, pictures shall be provided to the COR of the completed overhauled engine, the engine inside the container bagged & sealed and pictures of the container with the appropriate markings. Pictures shall be provided of all sides, front & back of the engine, reduction gear and container.

A DHS 700-21 form shall be filled out and signed by the contractor and submitted to the COR before shipping the propulsion unit back to the SFLC.

6.0 NOTES

6.1 Government & Commercial Document Sources

6.1.1 Government Documents

b. DOD & Navy Publications & Forms (Other Than DODISS) Naval Publication and Forms Center 5801 Tabor Ave.

Philadelphia, PA 19120 215-697-2000

c. USCG Surface Forces Logistics Center 2401 Hawkins Point Rd.

Baltimore, MD 21226-1792 410-762-6472 Attn: SBPL Contracting Officer

6.1.2 Commercial Documents

a. MTU/Tognum Corp.

39525 MacKenzie Drive Novi, Michigan 48377 248-560-8282

b. American Society for Testing Materials (ASTM) 100 Barr Harbor DR.

P.O. Box C700 West Conshohocken PA. 19428-2959

d. American Society for Quality Control 611 East Wisconsin Avenue Milwaukee, WI, 53202

e. Twin Disc Corporation 1328 Racine Street Racine, WI, 53403-1758

6.2 Appendices - The following appendices apply:

6.3 GLOSSARY

e. Engine: - MTU 60 Series DDEC IV Marine Diesel Engine

f. Overhaul: - Overhaul components with O.E.M. parts to O.E.M. new specifications

g. KO: - Contracting Officer

h. COR: - Contracting Officer’s Representative

Appendix A Core Condition Report

Work Order #_________________________________ Port/Stbd ____________________________________ Contract/Task Order #_______________________________ Engine Serial # ________________________________

Core Acceptance is based on the following:

a. Core must be in the configuration of Master Serial Number

b. Core must have no non-operational damage

c. Core must be a complete unit and not disassembled

NOTE: Missing parts from Appendix A are to be replaced and priced as per section B of this contract.

a. Core acceptable_______________________, non-acceptable_____________ Remarks _______________________________________________________

b. Metal shipping crate: Acceptable__________, non-acceptable_____________ Remarks _______________________________________________________

Note 1: The core condition report shall include photographs of engine; front, right side, left side, and rear views to include serial number in picture frame.

Note 2: List all discrepancies with Propulsion Unit including all damaged or missing parts identified by name, part number and comments.

APPENDIX A CONTINUED

APPENDIX A (CONTINUED)

Additional Comments ____________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

Contract/Task Order Number:_________________

Date:_________________________________

Unit Serial Number:_____________________

Total

Appendix B

DISASSEMBLY INSPECTION REPORT

Disassembly Inspection Report

Appendix B

Each marine engine shall be tested by the contractor and shall be tested using an approved test plan and all requirements outlined in this specification for the marine engine as per Detroit Diesel Shop Manual 6SE660.

1.0 Engine Test Requirements

1.1 The equipment used to record/provide the dynamometer test readings shall have the capability to print required parameters in a computerized format. During the final acceptance test, the Coast Guard Representative shall have the capability to visually monitor all required parameters as detailed in MTU Manual MS25056/00E (dated 1/2012) simultaneously.

1.2 Each marine engine shall be fitted with all "engine" equipment, with the exception of the alternator. This equipment shall be "Contractor Supplied" and used for each engine test.

1.3 The engine shall be tested as per the dyno test specifications of Appendix C. After the final dyno test is accepted by a Coast Guard Representative, all filter elements shall be replaced.

1.4 Any unusual noises, external leakage, or if any other noncompliance to this specification, as determined by the Coast Guard Representative, shall be cause for the marine engine to be found unacceptable.

1.5 The Government reserves the right to witness any part of the overhaul and testing requirements set forth in this specification.

1.6 Upon final acceptance the contractor shall provide the Coast Guard copies of all test results.

1.7 The following MTU rating data shall be maintained during the dyno testing:

Appendix C

ENGINE TEST REPORT

APPENDIX C (CONTINUED)

DYNAMOMETER ENGINE TEST REPORT

Date Serial Number ______________

Contract/ Task Order Number Model Number _______________

A. PRE-STARTING

Step 1

PRE LUBE OIL SYSTEM

Step 2

PRIME FUEL

SYSTEM

Step 3

ADJUST VALVES

Step 4

TIME INJECTORS

Step 5

ADJUST GOVERNOR

Step 6

ADJUST INJECTOR RACKS

TIME

AT

SPEED

IN

MINUTES

TIME

R.P.M.

B.H.P.

WATER

TEMP.

LUBE

OIL

PRESS.

1. Check oil at rocker mechanism

START

STOP

2. Inspect for lube oil leaks

3. Inspect for fuel oil leaks

4. Inspect for water leaks

5. Check and tighten all external bolts

6. Check torque on all manifold/turbo fasteners

D. INSPECTION AFTER BASIC RUN-IN

1. Re-torque Cylinder Head & Rocker Shaft Bolts

4. Re-adjust Governor Cap

2. Re-adjust valves (hot)

5. Re-adjust Injector Racks

3. Re-time injectors

6. Re-torque fuel jumper lines

E. FINAL RUN-IN

B.H.P.825 ± 5%

AIR INTAKE MANIFOLD PRESSURE

FULL LOAD

76hg or 37.32 PSI

EXHAUST BACK

PRESSURE F/L

2.5” Max

CRANKCASE

PRESSURE F/L

3.0” Max

START

STOP

NO LOAD

Min

2300 RPM

FULL LOAD

Min 2300 RPM

PSI

Hg

H²º

FUEL PRESSURE TEMP

158 ° Max

FUEL OIL PRESSURE

RET. MAN.

50-70 PSI

J/W WATER TEMP

188° Max

LUBE OIL TEMP

230° Max

LUBE OIL PRESSURE

IDLE SPEED

650 RPM

FULL LOAD

50 psi ± 5%

IDLE

25 psi ± 3%

PSI

RPM

F. INSPECTION AFTER FINAL RUN-IN

Temperature of Dyno Test Cell

Raw Water Pump Delivery pressure

Oil Viscosity Test (Falling Ball – Less then 1.5%)

Water Temperature at oil cooler inlet

K-2 Throttle Interrupt

Final Run OK’D Dynamometer Operator : Date:

2.0 MG-5114SC General Test Requirements

2.1 Readings as detailed in this Appendix are to be followed as per OEM standards for spin testing. These recordings of the test procedure shall be filled out and submitted as part of the required test report. The contractor may use a similar test report in lieu of this report as long as the same information contained in this appendix is included.

2.2 MG-5114SC Reduction Gear Parameters

a. Operating pressures of the transmission shall be recorded while spin testing at a minimum of the test Range RPM. All readings shall fall between the specified pressures or the transmission is not acceptable.

a.

b. Any external leakage shall deem the transmission unacceptable.

c. The oil used shall be in accordance with MIL-L-2104F Grade 10 and specific to the gear being tested.

a.

b.

c.

d. Oil temperature shall be maintained between 85 and 95 degrees F at all times during the test.

Date: Time: Facility:

MRG S/N:

FWD

205-265

NEU

15-65

REV

205-265

Remarks: Passed Failed

**THIS PAGE ATTACHED TO OVERHAULED ENGINE UPON COMPLETION**

This item has a warranty for whichever comes first:

1 year of operation from installation Or 1,000 hours of operation

If any discrepancies are noted upon receipt:

CALL THE WARRANTY HOTLINE:

USCG SURFACE FORCES LOGISTICS CENTER

SMALL BOAT PRODUCT LINE

CENTRAL ENGINE OVERHAUL PROGRAM

COMMERCIAL (410) 762-6237

AFTER HOURS (443) 306-4811

The following information is needed when calling SFLC:

Date Received

Date Installed

Engine Serial No.

Engine Hours

Port/Stbd

Vessel Hull No.

APPENDIX D (CONTINUED)

**THIS PAGE ATTACHED TO OVERHAULED ENGINE UPON COMPLETION**

GENERAL CHECKS UPON RECEIPT OF ENGINE

1 A complete inspection should be made of the engine’s condition.

2 Inspect the jacket water, fuel oil, lube oil and raw water systems for preservations remaining in these systems.

· Jacket water system must be flushed and new coolant added.

· Fuel system must be flushed completely with diesel fuel.

· Do not operate engine until the appropriate fluids are added.

3. Preservation tags on the engine will tell you to what extent the unit has been preserved and what should be done for de-preservation before operating the engine.

4. Uncover all taped and plugged openings prior to connecting all hoses and lines.

5. Ensure that all lube oil lines left on board are flushed and all filters are changed.

6. Ensure the engine will bar over by hand.

7. Check engine mounts.

THINGS THAT WILL NOT VOID THE WARRANTY

Preventative maintenance as set forth in P.M.S. manual may be performed.

Troubleshooting is approved, as long as the troubleshooting is in accordance with Tech Pub No. 6SE660.

Repairs are to be performed only after contacting Surface Forces Logistics Center, Small Boat Product Line, (410) 762-6237/6790/6235. After hours call (443) 306-4811 Alternate (443) 790 2448.

Emergency repairs/replacement of parts may be performed, but notify Surface Forces Logistics Center, Small Boat Product Line as soon as possible afterwards.

SOME THINGS THAT WILL VOID THE WARRANTY

Changing subassemblies Changing thermostat Removing the L/O cooler cores Changing the exhaust manifold assembly Removing gear housing

PAST INSTALLATION PROBLEMS

Cross connecting lube oil lines during installation.

Failure to flush lube oil lines coming from the boat.

Appendix C

Marine Gear Testing

Overfilling lube oil sump.

Appendix E

Time Compliant Technical Order (TCTO) & OEM Service Bulletins

1. Alfdex Breather System on Series 60 Marine Engine: ECP-177 MTU Reference No: VCNM-2011-06-0001 (Attached)

2. MDE Hot Start TCTO 5030.3 (Attached)

Appendix F

CUMULATIVE TRACKING REPORT SUBMIT BY THE 15TH OF THE MONTH

Work #

Task Order#

Date Received

Appendix G

MTU 60 Series Engine Mandatory Replacement Parts

ENGINE CONTAINER PARTS

Container Gasket P/N MTUS60CTRGSKT

Phelps Industrial Products Inc, Balt, MD

Appendix H

MTU 60 Series Contingency Replacement Parts

Appendix I

Contractor’s Technical Representative Condition Found Report

Representative Name:

Date:

Time Arrival:

Time Departure:

Unit:

POC:

City:

State:

Address:

Zip:

Hull Number:

Tel #:

Engine Serial Number:

Stbd/Port:

Date Installed:

Hours:

Contract #:

Task Order #:

Contractor Name:

Contracting Officer:

Engine Model #:

Condition Found

Repairs Required

Parts Required

Parts Expended

Recommendations

Appendix J

MG 5114SC

MANDATORY REPLACEMENT PARTS LIST

Appendix K

MG 5114SC

CONTINGENCY REPLACEMENT PARTS LIST

Appendix L ACMS Record

Appendix M Engine & Marine Gear Special Application Mandatory Parts

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